Modular raceway with base and integral divider

ABSTRACT

Raceway modules of predetermined length are joined by couplers designed to allow optional gaps between the T-shaped raceway base plate portions. Upper and lower L-shaped raceway covers are separately snapped out the base, allowing electrical and data/communication devices to be provided in staggered relationship, and anywhere along the raceway. The lower L-shaped raceway cover configuration allows outlet devices to be provided in the lower side of the raceway. The T-shaped base plate has pre-punched knock-out openings and mounting holes provided in a predetermined pattern, and pre-punched lines of weakening, that simplify the installation process. The couplers come in several lengths and configurations, to bridge crossing raceway or other obstructions, and to provide continuity in the gaps between the raceway modules. Pre-wired cover components are fitted with spaced outlet devices for installation in areas of a room that require such service.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of prior U.S. patent application Ser.No. 11/035,477, filed Jan. 13, 2005, now issued as U.S. Pat. No.7,262,371, hereby incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to conduit or raceways for electricalcabling.

BACKGROUND OF THE INVENTION

In certain types of building construction, e.g., retrofits, cinderblock, or the like, it may not be possible or practicable to runelectrical cabling (such as high voltage power lines and low voltagedata lines) through the building's walls. In such cases, modular racewayor conduit assemblies are often used to house and route cabling along awall or other surface. A typical raceway assembly includes a linear orelongate housing having at least one interior passageway thataccommodates a length of electrical cabling. (Such a passageway isreferred to herein as a “wireway.”) The housing is attached to a wall,and then the cabling is disposed in the interior of the housing. Tocover a given span, multiple segments of housing are deployed in anend-on-end manner.

In a typical raceway or conduit installation, sections of conduit mustbe cut precisely to match the wall span to be crossed by the raceway.Such cutting operations, e.g., through sheet metal, are time consumingfor installers. Additionally, because the sections are custom cut, it isdifficult to adjust or compensate for variations in spacing that stemfrom adding junction boxes, retrofit outlets, and the like.

SUMMARY OF THE INVENTION

An embodiment of the present invention relates generally to a modularraceway system having raceway base components of predetermined lengthdesigned to be mounted to a wall structure, or to be received by wallbrackets provided at predetermined intervals along a wall structure.Raceway wall brackets and/or couplers at the adjacent end portions ofthe raceway base components are designed to take advantage of the uniquecross section of the raceway base and provide a continuous enclosedstructure for the power and/or data cabling in divided, or separatedwireways, defined in part by an integrally formed divider in the base.

In another embodiment, the raceway base is provided with uniformlyspaced lines of weakening. Preassembly of the raceway base andassociated covers allows for modular use at installation, and alsoallows for fitting of the raceway to internal wall structures of abuilding without the need for custom cutting of the raceway base, suchas now required with raceway systems of the type available from TheWiremold Company of West Hartford, Conn. under its “3000” or “4000” twopiece metal raceway designations.

In another embodiment, the raceway base component is T-shaped. Separateraceway covers are provided for each of the two wireways defined in partby the T-shaped base component. The cover components are generallyL-shape in cross section and have end portions designed to mate with theforward or leading edge of the integrally formed divider defined in thebase, and to mate as well with the longitudinally extending marginalupper and lower edges of the base. Upper and lower cover components aremounted to the base, and offer flexibility in the placement of power anddata/communication outlet devices in one or the other or in both ofthese cover components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view showing the various components ofa first embodiment of the present invention relative to a wallstructure.

FIG. 2 is an exploded view of the components of the present invention asadapted for use in a modular raceway system that not only includespreassembled cables in the various raceway sections, but also includingpre-wired electrical outlet devices in the lower raceway.

FIG. 3 illustrates the raceway components of the present inventiontaking advantage of the downwardly open receptacles in the lowerraceway, as well as the staggered mounting for outlet devices in theupper and lower raceway covers. Also shown in FIG. 3 is an alternativearrangement where the outlet devices are clustered at a single locationin the raceway. This alternative embodiment illustrates a raised devicebox to provide additional through-put for the cabling in the wirewaysdefined by the raceway base and cover in accordance with the presentinvention. FIG. 3 also illustrates in exploded relationship the geometryof device brackets and device bracket “covers” such as are suitable foruse in a raceway of the type disclosed herein.

FIGS. 4 a-4 c show in several schematic views the advantage to providingpredetermined length raceway base sections together with brackets forsupporting these raceway base sections, to mount on a wall structure ofvarying length, yet with the same raceway components. These figures alsoillustrate the lines of weakening provided in the raceway base toachieve somewhat shorter raceway sections for wall lengths that requireless than these “minimum length” raceway sections.

FIG. 5 is an assembly view illustrating the use of modular raceway inaccordance with the present invention in a particular installation andillustrates the various internal and external elbows, T-shapes, and flatelbow configurations necessary to provide a complete installation in aparticular building environment.

FIG. 6 shows another alternative installation for running raceway of thepresent invention around an obstacle or column, and/or around anexisting conduit or other smaller obstacle in the path of the raceway.

FIG. 7 shows in exploded relationship the various components required toinstall outlet device brackets in the lower wireway of a raceway inaccordance with the present invention.

FIG. 8 shows in cross section the assembly of the components illustratedin FIG. 7.

FIG. 9 shows in perspective view the assembled components of FIG. 8.

FIG. 10 is an end view of an L-shaped device bracket for assembly withthe T-shaped base between aligned cover components associated with thetop or upper wireway.

FIG. 11 is a top perspective view of the device bracket shown in FIG.10.

FIG. 12 is a rear perspective view of the device bracket of FIGS. 10 and11.

FIG. 13 is an exploded perspective view of an alternative design for adevice bracket with a downwardly facing outlet device and enclosure andescutcheon components for assembly therewith.

FIG. 14 is an exploded rear quartering perspective view of the devicebracket and associated components.

FIG. 15 is a bottom view of the assembled components from FIGS. 13 and14.

FIG. 16 shows a T-shaped raceway base 220 having an integrally formeddivider, and the same lines of weakening provided at predeterminedintervals. Raceway covers 260 and 280 (see FIG. 17) can be shaped intoassembly with the base as described above. To join aligned raceway basecomponents to one another at installation, couplers 250, 250 are shapedinto the wireway defining walls of the T-shaped base. (FIG. 17 shows thecouplers 250, 250 secured into the raceway base 220 in more detail.)

FIG. 16 a shows a T-shaped base 225 having spaced lines of weakening,and alternately arranged knock-out openings in the web, and in the basefor mounting to a wall structure. The knock-out openings provide accessfor wiring between wireways.

FIG. 17 is a vertical section through an assembled base 220 and coverpair 260 and 280, with a pair of raceway couplers 250, 250 snapped intothe raceway base for holding adjacent base members in alignment. Notethe openings 250 a, 250 a for receiving screw fasteners S, S. Covers 260and 280 cooperate with the T-shaped base 220 to define separate wirewaysfor the power and data/communication cables.

FIG. 17 a shows a preferred one-piece raceway base construction 220 a.

FIG. 17 b is a view of the base in FIG. 17 a, assembled as in FIG. 17.

FIG. 18 is a perspective view of two aligned raceway sections 200, 200that are joined by a transition fitting, and bridging or linking onewireway with another raceway of smaller capacity.

FIG. 19 is an exploded perspective view of some of the assembledcomponents provided between the assembled raceway sections of FIG. 18.

FIG. 20 is an exploded perspective view similar to FIG. 19, but withoutthe raceway sections, which shows the raceway couplers provided in thetop and bottom wireways defined by the raceway base plate and theraceway covers.

FIG. 21 shows two aligned raceway sections and a transition fittingsimilar to that shown in FIGS. 18, 19 and 20, but instead of providingaccess to wiring from and to another raceway 506, the fitting 508 servesto bridge raceway 506 without any cross feeding of cables or wires.

FIG. 22 shows the FIG. 21 assembly, but without the raceway covers inone base plate, and without the transitions fitting cover.

FIG. 23 shows the FIG. 21 assembly, but without the raceway base andcovers, to better illustrate the unique coupling means comprising twoL-shaped coupling elements arranged alongside one another ancoextensively with respect to the spine (not shown) of the raceway base.

FIGS. 24-26 show a raceway cover component, such as described above,having an L-shape and mounted on a raceway base to and from a wireway.The cover has cutouts to receive additional plugs similar to those soldby The Wiremold Company.

FIG. 27 shows a lower raceway cover component 271 with pre-wired outlets275 a in the lower wall of the cover, rather than in the forward wall asdepicted in FIGS. 25 and 26.

DETAILED DESCRIPTION

Turning now to the drawings in greater detail, a wall structure isindicated generally at W1 and W2, defining an internal corner as shown,to represent the environment where a raceway of the present inventioncan be provided. See, for example, FIGS. 5 and 6, where both internaland external corners are illustrated, and where dropdown racewaysegments are provided for bringing electrical cables to the raceway.

With reference to FIG. 1, in accordance with the first embodiment of thepresent invention, a modular raceway is provided, and includesstandard-length raceway sections of length “L” that can be secured tothe walls W1 or W2, by wall brackets as indicated at 100, 100 a. Cornerbrackets can be fabricated from these unique wall brackets 100, asindicated at 101. Thus, the corner bracket 101 may comprise individualbrackets fabricated from the wall brackets 100, 100 a, to form a cornerbracket 101. It will also be apparent that this same approach can beused to form a corner bracket that can be utilized at an externalcorner.

A feature of the present invention is that the raceway assemblies 200,200 are of standard length (L), preferably between 4-8 feet, and arepre-wired. Thus, the raceway assemblies 200 can be assembled with themounting brackets 100, 100 a so as to leave a gap “G” between the endportions thereof. The internal wiring for each raceway assembly can befilled with connectors (not shown) or conventionally connected by wirenuts or the equivalent. The gap G can be closed by a short raceway slipcover member 300, which is of U-shape, and has an internal contour tofit over the external contour of the raceway covers in the assemblies200, 200, and to overlap these assemblies as shown in FIG. 3 forexample. Alternatively, the gap G in the raceway assemblies 200, 200 canbe used to provide an obstacle clearance component such as shown at 400and 500 a in FIG. 6. More generally, this gap G can be utilized toaccommodate T-fittings, outlet device brackets and slips covers,internal and external elbows, and flat elbows, all as shown in FIG. 5.

The raceway assemblies 200, 200 comprise a T-shaped base component suchas shown at 220 in FIG. 7, plus two raceway cover components 260 and280, each being of L-shape and snapped into the base 220 as suggested inFIG. 7. This configuration allows outlet devices to be placed at anylocation in the raceway assembly, and in either one or both of the upperand lower covers. FIG. 7 shows one outlet device for assembly in thefront wall of the lower wireway between spaced apart raceway covercomponents (one shown at 280).

FIG. 2 shows the same components as depicted in FIG. 1 except that theraceway assemblies 202 are not only pre-wired, but are also fitted withpre-wired outlet devices. Pre-wired raceway of this type is available,but not in with an L-shaped cover used with a T-shaped raceway base toachieve the results set forth herein. FIGS. 24-26 show this assembly ingreater detail and will be described in greater detail below.

Turning next to a detailed description of FIG. 3, various configurationsfor mounting outlet devices are illustrated for use with a racewayassembly constructed in accordance with the present invention. Forexample, in the gap G between adjacent raceway assemblies 200, 200, anassembly similar to that shown at 310 in FIG. 5 can be installedproviding a multitude of outlet devices, including a “down light.” As aresult of the unique L-shaped configuration for the raceway covers, itis possible to provide outlets in the downwardly facing side wall of thelower raceway cover.

Individual device brackets for both the upper and lower wireways definedin the raceway of the present invention are indicated generally at 320and 340 in FIG. 3, each being designed to accommodate a device such asan outlet plug. A cover or half cover is provided for each of thesedevice brackets, and the upper cover may include a frame to accommodatedata ports while the lower half cover may include a snap-in outletdevice plate, or the outlet device plate can be provided in one piecewith the half cover as described hereafter.

Still with reference to FIG. 3, and in locations where the adjacentraceway assembly end portions abut, so as to provide a continuous backplane for the raceway in a manner to be described, a somewhat shorterraceway coupling slip cover 390 can be fitted as shown. Furthermore, theopportunity for providing downwardly facing outlet devices permits powercabling such as indicated at 395 to be hidden from view and to beprotected from the environment. This location for outlet plugs providespower leads 395 in a protected area below the raceway, and between theraceway and the floor.

FIGS. 4 a-4 c illustrate the flexibility of raceway assembliesconstructed in accordance with the present invention, and show insomewhat schematic fashion the support brackets 100 together withaligned raceway assemblies 200, 200. In FIG. 4 a, the raceway assemblies200, 200 are shown in an abutting relationship. In FIG. 4 b, the racewayassemblies 200, 200 are shown in a spread relationship so as to providea gap “G” between the end portions of the adjacent aligned racewayassemblies 200. FIG. 4 c illustrates a feature of the raceway base ofthe present invention whereby lines of weakening 210, 210 are providedincrementally along the length L of the raceway base. As a result ofthis configuration three standard length (L) raceway segments 200, 200,each eight feet in length for example, can be used to accommodate eithera 24 foot span of wall, or can be expanded to provide an extra one footfour inches along the wall as a result of the gaps G provided betweeneach of the raceway assemblies. The scoring of the eight-foot racewaysections in predetermined increments allows even more variation in theoverall raceway length that can be accommodated with a minimum ofinstallation effort.

In a preferred embodiment, to be described with reference to FIG. 16 a,these lines of weakening are only 4 inches apart, as shown at “X.” Amore convenient fit to the convention stud spacing (16 inches or 24inches) in conventional wall structures can be achieved with thepre-punched base plate mounting holes 502, 502 spaced 2 inches fromevery other line of weakening (e.g., spaced “X/2”), providing a spacingbetween mounting holes of “2X .” The same spacing “2X” is providedbetween the knock-out openings in the web portion of the T-shaped baseas shown in FIG. 16 a. Finally, the slip covers, 300 for example, arepreferably half again as long as the spacing X, or 1.5 times X of thelines of weakening 210, 210 in the preferred embodiment (e.g., 6 inchesfor the preferred 4 inches spacing).

It is noted here that installers of present day raceway must useprecision cutting tools that are designed to sever a rather heavy gagesteel raceway base, that is generally of U-shape. Often times the cut isnot square, or otherwise of sufficient precision to satisfy either ULrequirements, or the installer/customer's needs.

Although present day covers for use with conventional U-shaped racewaybase configurations can be conveniently cut because they are flat, theflanges on the back side of the these covers can lead the installer touneven cuts, resulting in an imperfect raceway installation. Even theuntrained eye can be expected to pickup defects such as these. Thepresent invention effectively obviates or at least minimizes theopportunity for such imperfections.

The purpose then of the present invention is to provide a unique racewaysystem that is not only of modular construction as mentioned above, butthat also includes a raceway base which is provided with convenientlylocated lines of weakening 210, as described above with reference toFIGS. 4 a-4 c. Such a raceway system leads to greater flexibility in thelocation of outlet devices in the one wireway associated with the powerleads, and in the adjacent wireway associated with the data/telecomcabling. See for example in FIG. 3 where the “activations” for bothpower and data can be accommodated “anywhere” along the length of theindividual wireways rather than requiring all “activations” to beprovided in an oversized multipurpose installation such as illustratedat 310 in FIG. 3. Such an installation is possible in the presentraceway system.

Turning next to FIG. 7, and in accordance with the present invention, amodular raceway system of the present invention comprises elongatedraceway base plates 220 having the lines of weakening such as indicatedgenerally at 210. Each base plate includes a forwardly projecting webportion 212 formed integrally with the back plate 214, either by spotwelding or in the event the material is suitable by extrusion. ThisT-shaped base configuration gives rise to advantages not available inmore conventionally shaped raceway base structures. As mentioned above,a 4-inch spacing between adjacent lines of weakening 210, 210 ispreferred. Pre-punched holes spaced 2 inches from the lines of weakeningalso contribute to efficiency during installation.

In prior art raceways, of the type made from rolled steel for example,the raceway covers span the opening defined by a U-shaped base. See forexample the two-piece steel raceway available from The Wiremold Companyof West Hartford, Conn. under their 6000 and 4000 style two-piece metalraceway. The present invention on the other hand provides a raceway baseplate that is of T-shape cross section such that the forwardlyprojecting web portion defines a divider 212 between two adjacentwireways, that are further defined by separate wireway covers 260, 280.This configuration allows these raceway covers 260 and 280 to bepreassembled, or separately assembled with the raceway base 214, andconsequently provides opportunity for the placement of outlet devices instaggered locations along the raceway as suggested in FIG. 7. Installingindividual outlet devices, in one or the other of these separatewireways provides an advantage over the prior art two-piece metalraceways.

Still with reference to FIG. 7, the covers 260 and 280 are preferablyidentically configured, and the corresponding wireways also of equalcross-sectional area or volume. The lower raceway cover 280 is shown tobe coextensive in length with that of the upper raceway cover 260 inFIG. 7, but this equivalency is not required. Each cover component canbe of any length. Thus, individual outlet devices associated with eachof these raceways can be provided in staggered relationship along eachwireway so the raceway assembly can take a variation of forms as shownin FIG. 3 and FIG. 7.

Turning now to a more detailed description of the several ways in whichoutlet devices can be mounted in the raceway assembly, an L-shapeddevice bracket 270 is shown in FIG. 7, and includes an opening 270 a forreceiving an outlet device, such as indicated generally at 251. TheL-shaped device bracket 270 includes rearwardly extending lower portions270 b and 270 c, which have spaced-apart end portions 270 d that areidentically formed so as to be received on the angled flange 214 a thatextends the full length of the raceway base 214. The socket definingportions 270 d of the L-shaped device bracket 270 are received by theflange 214 a and allow the installer to pivot or snap the device bracket270 in place, and in assembled relationship with the downturned lip 212a of the divider 212 on the raceway base. The device bracket 270 alsohas inwardly bent flanges that define end portions 270 e, 270 e providedspecifically for this purpose.

It will be apparent that the L-shaped device bracket 270 can beconfigured to receive outlet devices such as that shown at 251. Outletdevices with different configurations, as for example data/communicationjacks, can also be provided in the device bracket 270, and mounted inthe upper wireway defined between the raceway base 214 and cover 260. Adownwardly inclined flange 214 b on the raceway base 214 cooperates withthe upturned flange 212 b on the divider wall 212 for this purpose.Since both wireways are preferably identical, the same device bracket270 can be assembled in both the upper wireway and the lower wireway.

Still with reference to FIG. 7, a cover plate 290 is adapted to fit overthe outlet device 251 and is fitted to the raceway itself even as doesthe device bracket. This cover plate overlaps the cover segments 260,280. The cover plate 290, like the device bracket 270, is generallyL-shape in cross-section, and includes a rearwardly projecting wall 290b, having a socket shaped end portion or flange 290 d, which is adaptedto engage the aforementioned flange 214 a of the raceway base. Theflange 290 a fits between the socket portions 270 d, 270 d on the devicebracket 270. As so constructed and arranged, the cover plate 290 can beassembled over the device bracket by providing this socket flange 290 din the space between the leg portions 270 b, 270 c of the devicebracket, and pivoting the cover 290 in place over the outlet device 251.The upper marginal edge 290 a is configured to be received between theportions 270 e of the device bracket as assembled with the base flange212 a. A secure assembly is provided for the outlet device 251. Steelmaterial is preferably selected for fabrication of the raceway base andcovers and provides continuity or grounding throughout the assembly of araceway constructed in accordance with the present invention. So too thedevice bracket 270 is also fabricated from an electrically conductivemetal material.

FIG. 8 shows in cross-section the assembly described in the proceedingparagraphs, and illustrates the interlocking arrangement provided forbetween the raceway base flange 214 a and the socket defining endportions of the rearwardly projecting legs 270 d of the device bracket.Also shown in FIG. 8 is the rearwardly projecting portion 270 e of thedevice bracket, which cooperates with the angled marginal edge 212 a ofthe divider 212. The bracket cover 290 has openings, best shown in FIG.7, for receiving the outlet device 251. The outlet device itself maybesecured to the device bracket 270, preferably by conventional screwfasteners (not shown).

Although the staggered relationship between the devices in the upper andlower wireways illustrated in FIG. 7 is an advantage of the presentinvention, it will be apparent from FIGS. 7, 8 and 9 that outlet devicescan be stacked one above the other in a conventional configuration.Thus, the raceway system of the present invention has all of theadvantages of prior art systems, and has added advantages over prior artraceway systems.

FIGS. 10, 11 and 12 illustrate a device bracket 370 of slightlydifferent geometry. The device bracket 370 is designed to accommodate amore conventional cover plate 390. The rectangular-shaped, conventionalcover plate 390, which is representative of present day outlet devicecover plates generally, can be fastened to the device bracket 370 assuggested by the broken lines of FIG. 11. As shown in FIG. 10, thedevice bracket 370 has a socket defining portion 370 d formed on theinner top side of the L-shaped bracket, and this side 370 b is orientedat an angle so as to form the L-shape with respect to the device bracketwall 370 a, that will accommodate the outlet device itself.

FIG. 11 illustrates the device bracket 370 of FIG. 10 in a front topperspective view, with the outline of a conventional cover plate 390being illustrated in broken lines to show how the device bracket 370accommodates both the outlet device and the conventional cover plate.Suitable openings are provided adjacent to the outlet device opening inthe device plate 370 for receiving both the screws associated with aconventional outlet plug, and other styles of cover plates associatedwith non-metal raceways.

Still with reference to the device bracket 370, FIG. 12 illustrates theshortened socket portion 370 d of the device bracket 370, which engagesthe downturned flange portion 212 a of the divider 212 in the base 214of the raceway. A rearwardly projecting flange 370 e provided on thelower edge of the device bracket 370 engages the flange 214 on themarginal edge of the web of the raceway base. Grounding screws G, G areprovided to securely anchor the device bracket 370 in place, and toserve as a continuity or grounding connection as between the devicebracket 370 and the raceway cover of the raceway assembly.

FIGS. 13, 14 and 15 show still another version of outlet device bracket370, one that also allows the device to be mounted between raceway covercomponents in the raceway assembly in order to provide the outlet plugat a location that does not detract from the overall appearance of theraceway assembly itself. More particularly, the device bracket 370 is somounted that the outlet device 251 faces downwardly, affording theopportunity to hide both the outlet plugs from view, and to make thewires extending to and from that plug much less noticeable than is thecase with present day outlet device-equipped raceways of the surface orwall mounted type.

FIG. 13 also shows a slightly modified configuration for the divider 312in the raceway base 320, the raceway base being otherwise similar tothat described previously, and having marginal edges 314 a and 314 bdefined along the marginal edges of the base, and having angled portions312 a and 312 b defined along the free end portion of the web or divider312. Thus, the raceway base 320 is quite similar to that describedpreviously with reference to the raceway base 220, and preferablyincludes lines of weakening 310 and mounting holes (not shown). It willbe apparent that device brackets of the type described previously withreference to FIG. 7 and FIGS. 10-12 inclusively can also be used withthe alternative raceway base plate 320 of FIG. 13.

In order to take advantage of a downwardly facing outlet plug 251 suchas shown in FIG. 13, a unique configuration is provided for the devicebracket. The device bracket 370 of FIG. 13 is shown in explodedrelationship to the raceway base, whereas in FIG. 15 the device bracketis shown in an assembled relationship with the raceway base. A racewaycover is also shown assembled with the raceway base in FIG. 15.

With reference to FIG. 13, the device bracket 370 can be seen to have agenerally U-shaped configuration, the lower legs of the “U” being spacedapart to receive the outlet device 251. The upper legs of the U areoriented parallel to these lower legs, and are provided alongside thedivider 312. The outlet device 251 and its device bracket 370 areisolated from the lower wireway by a retaining box 375 mounted on thedevice bracket 370. These components are held in assembled relationshipby the ears 375 a on box 375 that cooperate with slots 370 a in thedevice bracket for this purpose. Retaining box 375 not only affordsprotection for the connections made with the outlet plug 251 atassembly, but also serves to define a protective passageway that willaccommodate wiring running through the lower wireway in the racewayassembly.

FIG. 14 shows these components from below, as adapted to be assembledwith the raceway base 320 to be provided between spaced raceway covers280. The cover plate 400 serves as an escutcheon plate for thedownwardly facing outlet plug 251. The socket portions 400 a and 400 d,provided at the ends of the L-shaped cover 400, allow snap-in assemblyof the cover 400. More particularly these socket portions fit onto theflanges 312 a and 314 a of the base 312. The cover plate 400 is designedto accommodate the outlet device 251, but other configurations (notshown) can be fabricated to accommodate other types of electricaldevices, such as jacks or down lights as shown in FIG. 5.

By way of summary and with reference to FIGS. 13, 14 and 15, it will beapparent that raceway assemblies fitted with an outlet device plate inthe downwardly facing wall of the raceway present an architecturallypleasing raceway appearance as this configuration obscures the outletplug from view. Thus, the eye of the observer does not pick up suchlocations for the outlet plugs as readily as with conventional racewaysgenerally. Further, the electrical cords that will be later plugged intosuch downwardly facing outlets located in the lower wall of the racewayare also obscured from view, giving rise to an improved appearance forthe space serviced by the raceway of the present invention, as comparedto conventional raceways generally.

In addition, this configuration puts the plug in a more protectedenvironment. Whereas conventional, present day raceways include a basecomponent of generally U-shape with vertically spaced top and bottomboundaries or walls formed integrally with a generally flat base whichis mounted to the wall, the provision for outlet devices in that lowerwall is virtually precluded, or at least rendered difficult, by virtueof the fact that the wall is integral with the base. In the T-shapedraceway base plate of the present invention, on the other hand, nobottom wall is required, and the bottom wall of the raceway is insteaddefined by the cover, leading to greater flexibility for locating outletdevices. More particularly, the cover's L-shape cross section affordsopportunity for mounting downwardly facing device brackets, and bracketsfor other purposes such as lights, without requiring any cutting away ofthe raceway base. Therefore, the raceway design of the present inventionaffords not only a more aesthetically pleasing appearance to theobserver, but also provides for functional advantages not readilyavailable with raceway configurations currently available.

As previously described with reference to FIGS. 4 a-4 c, racewaymounting plates can be provided at spaced intervals along a wall, andpreassembled raceway assemblies of predetermined length can be securedto these mounting plates to leave a gap between the adjacent endportions of the aligned raceway base plates. Thus, these mounting platesserve as coupling means to provide a continuation of the rear boundaryof the upper and lower wireways so that the wireways need not be definedby the wall, but as instead defined by the metal covers and the metalmounting plates at least in the areas of these gaps. As mentionedpreviously, the lines of weakening in the raceway base plates facilitatethe installation process in that the precise cutting of the raceway base(required with present day U-shaped two piece metal raceway generally)is rendered unnecessary, and the installer can instead make rough cutsor simply break apart the raceway base at a line of weakening.

It is also a feature of the present invention that these raceway baseplate components can be assembled directly to the wall without requiringmounting plates. In order to provide another form of coupling means, toform a continuation of the metal back plane for the wireways defined bythe aligned L-shaped raceway base components, the present inventioncontemplates individual coupling wireway elements, in the form of thecouplings shown at 250, 250 in FIG. 16. FIG. 16 shows a raceway baseplate 220 of T-shape cross section having a plurality of score lines210, 210 in the manner described previously with reference to FIGS. 4a-4 c. In lieu of the mounting plates shown in FIGS. 4 a-4 c, couplingmeans, in the form of elements 250, 250, are snapped into place betweenthe projecting T-shaped web 212 and the rear wall 214 of the racewaybase 220. More particularly, the marginal edges of each coupling memberor element 250 are received between the lip 212 b at the free endportion of the web 212, and the longitudinally extending marginal edge214 a of the back portion of the raceway base. See FIG. 16 for detailson the preferred form for the T-shaped raceway 225. With reference toFIG. 16 a, note the spacing “X” between the lines of weakening, and thespacing “2X” between the knock-out openings and mounting holes 502. X ispreferably a division of 16 and 24, and 4 inches has been found to be asuitable spacing X.

FIG. 17 a shows a preferred one-piece, metal raceway base configuration220 a with the top and bottom wireways, A and B respectively, defined bya web divider portion 212 formed with a double thickness, such that theweb 212 forms a 90° bend with respect to the base 215.

FIG. 17 b is similar to FIG. 17, but shows slightly different couplerelements 250 a, 250 a in combination with the base 220 a of FIG. 17 a.

FIGS. 17 and 17 b show the raceway coupling members 250 and 250 a asheld in place by screw fasteners S, S. The screw fasteners arethreadably received in openings provided for this purpose at the vertexof each coupling member 250 and 250 a. FIGS. 17 and 17 b also illustratethe nesting relationship between the back wall 214 and 215 of theraceway base 220, 220 a and these coupling elements 250, 250 a. It willbe apparent that these coupling elements 250, 250 a serve the purpose ofcoupling adjacent end portions of raceway base members as describedabove, without interfering with the raceway covers 260 and 280, thecover components being held in place by the same marginal edge portionsof the raceway base and the lips defined at the free end portions of theweb 212 all as described previously with reference to these racewaycovers 260 and 280. Thus, the separate wireways defined by the T-shapedraceway base 220, 220 a and the raceway covers 260, 280 are continuedand defined in part by these unique raceway coupling elements 250, 250a.

FIG. 18 illustrates raceway assemblies 200, 200 coupled together, but ina way such that a coupler cover 500 a also accommodates a T-connectionbetween the upper wireway and a smaller electrical conduit 500 orientedat right angles to the raceway of the present invention. The couplercover 500 a is provided with a knock-out opening to accommodate theconduit 500 and/or a large conduit can also be accommodated by reason ofa somewhat larger knock-out opening.

FIG. 19 shows the coupler cover removed, and illustrates a couplingelement 252 associated with the upper wireway having a cutout region 252a for receiving a bracket 255 designed to accommodate the conduit 500.As with the previously described couplings 250, 250, coupling element252 spans the gap between spaced but aligned raceway base components. Inaccordance with the present invention, cable guides 262 and 282 areprovided to afford some protection for the cables or conductors providedin the wireways defined by the T-shaped base and the raceway covercomponents 260 and 280. The cable guides 262, 282 are configured toallow such cables to pass through the wireways, when assembled with thecoupling element 252, but to allow cables within the conduit 500 to rundownwardly into the upper wireway, and to be fed in one direction oranother of the upper wireway shown in FIG. 19. Tabs 262 a on the uppercable guide 262 snap into slots 252 b provided for this purpose in thewall of the coupling element 252 for this purpose. Relieved areas 262 ballow cables within the conduit 500 to clear the cable guide 262. Thelower cable guide 282 may be used to provide an access point in thelower wireway for feeding wires from the wall structure into the lowerwireway. A port 285 is provided for this purpose in the lower couplingelement as best shown in FIG. 19.

FIG. 20 is an exploded view showing the upper coupling element 252having a relieved region 252 a for receiving the L-shaped bracket 255that serves to anchor the conduit 500 by means of tab 255 a, and toinclude a lower portion 255 b that defines a knock-out opening forcables run to the lower wireway defined by the raceway assembly of FIG.19. FIG. 20 also shows the coupling cover 500 a together with itsknock-out openings in the top wall for receiving conduits such asillustrated at 500, or larger conduit as dictated by the needs of aparticular installation.

FIG. 21 shows adjacent raceway assemblies of the present inventioncoupled as described previously to afford a bridge between the wirewaysdefined therein and a crossing raceway or conduit 506. Coupling 508 isprovided with knock-out openings in both its top and bottom walls forthis purpose.

FIG. 22 shows the crossing conduit 506 of FIG. 21 in greater detail,together with the raceway coupling elements 252 required to bridge thegap between the aligned ends of the raceway base components. From FIG.22 it will be apparent that the L-shaped bracket of the previous views(FIGS. 20 and 21) is not required, and it will further be apparent thatthe crossing conduit 506 does not feed cables to the wireways defined inthe raceway of the present invention. However, cable guides 262 and 282are utilized in the same manner as described above to facilitate feedingof cables in these upper and lower raceways.

FIG. 23 shows the coupling elements 252, 252 associated with the upperand lower wireways of FIGS. 21 and 22, as well as the cable guides 262and 282, and coupling cover 500 a with a knock-out opening patternsimilar to that of the coupling cover 500 a of FIG. 18.

In FIGS. 24-26 a raceway cover 270 has generally rectangular cutouts 270a for presenting outlet plugs 275 at longitudinally spaced predeterminedintervals along the cover. The cover 270 is similar to those describedabove and has longitudinally extending marginal edges of base plate asshown at the lower edge of base 320. An inner recess 270 c forms apocket to receive the edge 276 a of a device bracket 276, also ofL-shape, but fits into cover 270 to form a cavity for the outlet device275. An upper edge 276 b of L-shaped device bracket 276 fits into arecess defined at the top inside edge of cover 275 a, shown at 270 d.The device bracket 276 is of shorter extent than the outlet device 275,as indicated in FIG. 25.

As suggested in FIG. 24, power cables in the lower wireway of theraceway are connected to the terminals of the outlet devices in aconventional manner. These L-shaped covers 270 can be preassembled, assuggested in FIG. 26, for use with selected raceway assemblies of thetype described above, for simplifying the task of an installer.

FIG. 27 shows outlet devices of the duplex type mounted in thedownwardly facing wall of a raceway cover component 271.Data/communication devices (not shown) of appropriate size might also bemounted in this lower wall of lower raceway cover 271. This is so inspite of the preference for locating the data/communication cabling inthe upper wireway, and the power cables in the lower wireway of araceway assembly incorporating the present invention. The T-shaped basemember preferably has knock-out openings such as shown in FIG. 16 a thatallow wiring from the upper wireway to pass through the web portion ofthe T-shaped base for this purpose.

1. A modular raceway system comprising: first and second elongatedraceway assemblies having first and second elongated bases,respectively, each of said raceway assemblies further including: aprojecting web connected to the base, said base having upper and lowerplate portions for abutting a wall, and said plate portions having upperand lower marginal edges respectively, wherein the projecting web isjoined to the base intermediate said upper and lower marginal edges toform a T-shaped cross section without sidewalls so as to define upwardlyand downwardly open elongated wireways, said base web having a freemarginal edge with oppositely projecting elongated lips; and upper andlower elongated raceway cover components having elongated marginal edgeportions defining sockets for receiving said projecting lips on saidbase, and said cover components having opposite edge portions that matewith said upper and lower base marginal edges of said base, said upperand lower cover components cooperating with said base to further definesaid upper and lower wireways respectively; wherein the first base has alength such that the second base, when located adjacent thereto, can bealigned therewith and spaced there from so as to provide a range of gapspaces between the first and second bases; and at least one couplingmember cooperative with the first and second raceways and configured tosupport said bases in longitudinal spaced alignment with one anotheracross said range of gap spaces.
 2. The modular raceway system of claim1 wherein: the at least one coupling member comprises upper and lowerL-shaped coupling elements slidably received in said upper and lowerwireways, said coupling elements having end portions also of L-shape toconform to said T-shaped base cross section and cooperating with saidcover components to form upwardly open and downwardly open couplingwireways in said gap spaces, as continuations of said T-shaped bases andsaid wireways defined by the raceway bases and projecting webs.
 3. Amodular raceway system comprising: first and second elongated racewaybase plates; at least one coupling member for securing the first baseplate to the second base plate in an aligned relationship, said at leastone coupling member overlying the base plates for a connectiontherebetween when said base plates are spaced apart longitudinally by agap, wherein the at least one coupling member includes: end portionsslidably received by the base plates; and at least one intermediateportion between said end portions for spanning the gap between the baseplates, said end portions and said intermediate portion havingsubstantially the same cross section throughout the length so that arange of gaps can be accommodated; and at least one raceway covercomponent mountable to said base plates for spanning said gap andcooperating with the coupling member intermediate portion to define atleast one wireway that is enclosed, particularly at said gap.
 4. Themodular raceway system of claim 3 wherein said raceway base plates areT-shaped and said raceway cover components are L-shaped to define atleast two enclosed wireways that are separated by a forwardly projectingweb of said T-shaped base plates, the web and the base defining upwardlyand downwardly open elongated wireways that are enclosed by said covercomponents.
 5. The modular raceway system of claim 4 wherein thecoupling member is L-shaped in cross section, said coupling membercooperating with the cover components to define the upwardly anddownwardly open elongated wireways across said gap.
 6. The modularraceway system of claim 5 wherein the coupling member includes knock-outopenings for receiving smaller raceways oriented perpendicular to saidmodular raceway system.
 7. The modular raceway system of claim 3 furthercomprising at least one raceway slip cover for overlying spaced apartend portions of the cover components.
 8. The modular raceway system ofclaim 3 wherein at least one of the base plates and the coupling memberincludes a series of regularly spaced apart fastener apertures forconnecting the base plates and/or coupling member to a wall surface,wherein the apertures are spaced apart by a distance that accommodatesat least two standard wall stud spacing patterns.
 9. The modular racewaysystem of claim 8 wherein neighboring apertures are spaced apart byabout 8 inches, for accommodating wall studs that are spaced apart by 16or 24 inches.